Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A system and method for environmental testing and evaluation of non-destructive inspection (NDI) sensors is provided. The system has a structure having a plurality of NDI sensors to be tested. The system further has an environmental chamber containing heating elements and cooling elements for heating and cooling the NDI sensors when the structure is secured to the environmental chamber. The system further has an impact testing assembly positioned over the structure for impacting the structure. The system further has a data acquisition computer subsystem coupled to the environmental chamber and coupled to the NDI sensors. The data acquisition computer subsystem controls and monitors the heating and cooling elements, and collects and processes temperature and impact data acquired by the NDI sensors.

Abstract: A system comprises an automated fiber placement (AFP) machine and a layup mandrel tool supported by the AFP machine. The mandrel tool includes a truss core and a plurality of mandrel panels attached to the truss core to form a layup surface.

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A system comprises an automated fiber placement (AFP) machine and a layup mandrel tool supported by the AFP machine. The mandrel tool includes a truss core and a plurality of mandrel panels attached to the truss core to form a layup surface.

Abstract: A mobile platform is provided which has at least one component having an array of distributed piezoelectric transmitters and an associated array of distributed receivers. The receivers are configured to receive ultrasonic transmissions from the transmitters. Data from the receivers is stored in memory and processed through an algebraic reconstruction tomography algorithm which forms an image of the defect within the component. An algorithm is used to determine the position and size of the defect.

Abstract: A mobile platform is provided which has at least one component having an array of distributed piezoelectric transmitters and an associated array of distributed receivers. The receivers are configured to receive ultrasonic transmissions from the transmitters. Data from the receivers is stored in memory and processed through an algebraic reconstruction tomography algorithm which forms an image of the defect within the component. An algorithm is used to determine the position and size of the defect.

Abstract: A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.

Abstract: A system and method for detecting damage to a structure is provided. The system includes a voltage source and at least one capacitor formed as a layer within the structure and responsive to the voltage source. The system also includes at least one sensor responsive to the capacitor to sense a voltage of the capacitor. A controller responsive to the sensor determines if damage to the structure has occurred based on the variance of the voltage of the capacitor from a known reference value. A method for sensing damage to a structure involves providing a plurality of capacitors and a controller, and coupling the capacitors to at least one surface of the structure. A voltage of the capacitors is sensed using the controller, and the controller calculates a change in the voltage of the capacitors. The method can include signaling a display system if a change in the voltage occurs.

Abstract: A connector pad is provided having a base, a top opposite the base, and tapered sidewalls therebetween. The tapering minimizes stress concentrations when the connector pad is bonded into, or on the surface of a structure. The connector pad consists of a plurality of structural load carrying plies suitable for sandwiching a flat structurally integrated wiring array therebetween. A plurality of plated through holes formed in the connector pad enable access to the wiring array therein.

Abstract: The invention provides a fuel-tank system with an ultrasonic fuel-gauging system for an aircraft. The fuel-tank system includes a fuel tank, a transducer carrier tape covered with a separation barrier, and coupled to a surface of the fuel tank, and at least one ultrasonic transducer attached to the transducer carrier tape. An ultrasonic signal from at least one ultrasonic transducer is reflected from a fuel-air surface and a reflected signal is received by at least one ultrasonic transducer to determine a fuel level in the fuel tank.

Abstract: A connector pad is provided having a base, a top opposite the base, and tapered sidewalls therebetween. The tapering minimizes stress concentrations when the connector pad is bonded into, or on the surface of a structure. The connector pad consists of a plurality of structural load carrying plies suitable for sandwiching a flat structurally integrated wiring array therebetween. A plurality of plated through holes formed in the connector pad enable access to the wiring array therein.

Abstract: The invention provides a fuel-tank system with an ultrasonic fuel-gauging system for an aircraft. The fuel-tank system includes a fuel tank, a transducer carrier tape covered with a separation barrier, and coupled to a surface of the fuel tank, and at least one ultrasonic transducer attached to the transducer carrier tape. An ultrasonic signal from at least one ultrasonic transducer is reflected from a fuel-air surface and a reflected signal is received by at least one ultrasonic transducer to determine a fuel level in the fuel tank.